Mass production housing

ABSTRACT

A HOUSING SYSTEM COMPRISING A PLURALITY OF MODULAR SEGMENTS ARRANGED IN A BASIC PLAN MODULE TO FORM A HOUSE, APARTMENT, OR OTHER BUILDING ADAPTED FOR EXPANSION BY ADDITION OF SIMILR MODULES, EACH MODULE COMPRISING A STRUCTURAL SPACE FRAME ARRANGED FOR PERMANENT OR DE-   MOUNTABLE ERECTION AND HAVING ADJUSTABLE PEDESTAL FOUNDATIONS FOR LEVELING, A STANDARDIZED FLOOR DECK AND ROOF BASE UNIT, AND A MODULAR EXTERIOR WALL UNIT FRAME.

.Feb- 9 D. BAKER 3,564,786

MASS PRODUCTION HOVUSING ori inal Filed Nov. 15,. 1968 3 Sheets-Sheet 1 4 z I 8 G F W I m 3 W 7 I 2 7 I. G I F m 7 I 5 FIGS F IG.4

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3 S heets Sheet 2 D. BAKER MASS PRODUCTION HOUSING Feb. 23, 1971 Original Filed Nov. 15, 1968 INVENTOR W Ur FIG.

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United States Patent 3,564,786 MASS PRODUCTION HOUSING David Baker, 2141 Sudbury Place NW., Washington, D.C. 20012 Continuation of application Ser. No. 782,517, Nov. 15, 1968. This application Jan. 9, 1970, Ser. No. 1,834 Int. Cl. E04b 1/348; E04h 1/02 US. CI. 5279 Claims ABSTRACT OF THE DISCLOSURE This is a continuation of application Ser. No. 782,517, filed Nov. 15, 1968, and now abandoned.

OBJECTIVES The important object of this invention is to achieve a mass-produced housing system. In so doing, materials are selected with regard to strength, performance, and light weight, and are utilized in respect to simplicity, economy, feasibility in handling, erection, and transport.

An objective is that each space frame is to be the structural nucleus of this invention, and is to fit a module to represent a room volume or function thereof. Said frames or rooms when joined together are to form a complete house or other building, and to have the capability of expansion. For example, one module may contain a kitchenlaundry and foyer combination, one module may contain a bath and bedroom combination, one or two modules may contain a living room, one module may contain a dining room or a dining room and passage combination, and so on. These modules are to have the capability of combinmg in many sizes of houses, apartments, hotels or motels, classrooms, studios, offices, and so on.

{\n objective is to achieve a structural space frame which carries the principal loads as well as its own weight, but does not preclude the possibility of a wall or part thereof from acting as a load-bearing element. Within this frame, walls which are relatively thin can be used. They would be insulated as required and finished from among a wide selection of materials as desired for customer appeal both exterior and interior. Interior walls may be placed within the structural space frame module or may straddle more than one to achieve a variety of interior volumes or space.

An objective is to achieve footings which are adjustable so that the building segments can be leveled to take care of inconsistencies in excavation and to permit usage on irregular terrain, as well as subsequent adjustment in case of settlement.

An objective is to achieve a standardized floor deck and roof base unit to fit each structural space frame, and to develop a standardized exterior wall frame to also fit into the structural space frame. Said frame is to be made in a manner to permit the use of small or large windows so that the rooms may be oriented to the solar rays or to the north, south, east, west, and other directions.

An objective is to have a variety in the roof shapes, forms and lines. Each roof shape is to be a preformed or preassembled modular unit and is to fit on top of the roof base unit. The roof shapes are to be selected to form the roof of a building in a manner consistent with a pleasing appearance or an architectural style.

An objective is to achieve a modular segment, finished or unfinished, with or without walls, roof assemblies, or foundation pedestals, so that they can be shipped in assembled, partially assembled, or unassembled parts in order to reduce the amount of field erection wherever practicable and for shipping economy.

The foregoing and other objectives, important features, and advantages inherent in and encompassed by this invention wilt become apparent as a preferred embodiment of the same, and is disclosed by way of example in the ensuing specifications and accompanying sheets of drawings, the figures of which are described immediately below.

SUMMARY OF THE INVENTION This invention provides a novel structure especially suited for mass production prefabrication and readily adapted for arrangement according to the use and design dictates of the resultant structure.

DESCRIPTION OF THE DRAWINGS FIG. 1 is a fragmentary vertical section of a typical structural space frame.

FIG. 2 is a fragmentary part of the adjustable turning rod with reverse threads to screw into cores fitted within the upper and lower hollow tube pedestals.

FIG. 3 is an isometric view of a connector piece between the floor deck, roof base, wall frames, and the stanchions.

FIG. 4 is an elevation view of a typical interlocking bearing plate with top and bottom tapered prongs. The prongs set into the tapered core fitted in the hollow tube pedestal and the stanchions. The number of prongs to the bearing plate and the size of the bearing plate depend upon the number of stanchions which are joined.

FIG. 5 is an elevation view of a typical interlocking bearing plate with long and short prongs. The prongs are tapered and are set into a fitted tapered core inserted in the hollow tube stanchions at the roof line, and in the bottom hollow tube pedestal at the foundation line. The number of prongs to the bearing plate and the size of the bearing plate depends upon the number of stanchions which are joined including the hollow tube pedestals.

FIG. 6 is an enlarged plan of a section at the o1ning of a corner stanchion with the exterior wall frames, and shows the tapered core fitting provided for the vertical connection of the foundation pedestals and the stanchions to receive the prongs of the bearing plates which lock into it.

FIG. 7 is an enlarged elevation of a section at the oining of the corner stanchions with the fioor deck assembly and the exterior wall frames where the union takes place between floors in multistory construction.

FIG. 8 is an enlarged elevation of a section at the joining of the foundation pedestal with the floor deck assembly and the exterior wall assembly.

FIG. 9 is a fragmentary plan of a typical structural space frame showing parts of the adjacent space frames in a manner which illustrates in plan view the joining of the stanchions. For example, four corner stanchions are joined together to form an interior connection, three corner stanchions are joined together to form an exterior inside corner connection, and two corner stanchions are joined together to form an exterior side connection.

FIG. 10 is an isometric drawing showing an assembly of eight modular segments, each with a slope type of roof assembly which when joined together illustrates a four bedroom house with a traditionally styled shape of roof.

FIG. 11 is an isometric drawing showing an assembly of eight modular segments, each with a slope type of roof assembly which when joined together illustrates a four bedroom house which has an open court or atrium.

FIG. 12 is an isometric drawing showing a random arrangement of six modular segments to illustrate vertical as well as the horizontal joining of them for one level or multistory erection and showing several shapes of roof assemblies.

FIG. 13 shows some of the basic room modules encompassed by the structural space frame, and the plan of each module is used as a separate template to plan a house, apartment, or other building.

FIG. 14 shows single rooms and portions of rooms which are modular in plan and arranged functionally to put together the house shown in outline isometric form in FIG. 10.

FIG. 15 shows two illustrations of typical room modules in a transparent isometric projection. One module is of a kitchen-laundry and foyer segmental combination, and one module is of a bathroom and bedroom segmental combination.

FIG. 16 shows a plan of bearing plate shapes used to tie adjoining structural space frame stanchions together and adjoining foundation pedestal assemblies together with one, two, three, or four prongs per surface.

DESCRIPTION OF THE PREFERRED EMBODIMENT In the accompanying drawings like numerals are employed to designate like parts throughout the same. In this systems invention, the method of assembly and its parts are described from the foundation up. Note that a portion of the foundation pedestal footings, consisting of parts 5, 6, 7, and 16 can be installed with the structural space frame or separately. The assembly is as follows:

After a concrete base is installed, the interlocking hearing plates part are set in place at the required modular locations at the corners. The braced footing plates with slotted holes part 6 which are welded to the lower pedestals part 16 are set over part 5 as one assembly upon the concrete base and are bolted to the concrete base. The said lower pedestal part 16 contains the fitted tapered core to receive the prongs of the interlocking bearing plate part 5.

The adjustable opposite threaded turning rod and nut part 7 is installed over the foundation assembly aforementioned and then the upper part of the hollow tube pedestal part is installed which has a welded flange part 17 to accommodate cross bracing, and has a fitted core with inside threads part 13 placed in the bottom of it, and has a fitted core with a tapered inside part 12 placedin the top of it. The entire foundation assembly is leveled up by turning the turning rod and nut part 7 before proceeding to the next step. Set the foundation assembly plum, square, and true.

The interlocking bearing plates with the tapered prongs part 4 are inserted on the top of the foundation assembly; over the interlocking bearing plates part 4 insert the Z frame assembly part 11 which has a hole in the corners of the top side leg to line up and permit the passage of the tapered prongs to secure the base of the structural space frame assembly.

The hollow tube stanchions part 8 which contain the fitted tapered cores part 12 are installed over the corner interlocking bearing plates part 4, and on top of this install the interlocking bearing plate part 5 which has long prongs on one side and short prongs on the other side. If a fioor is to be added above this, then install the interlocking bearing plates part 4 with long prongs on both sides instead and continue as before.

The 2 frame assembly part 11 which has a hole in the corners of the top side leg to line up and permit the passage of the tapered prongs to secure the top of the structural space frame assembly is inserted over the interlocking bearing plates part 5.

The floor deck assembly part 2 which contains part 14 consisting of structural members located at points perpendicularly cross-wise in each directio d for gonal 4 bracing from corner to corner is inserted into the structural space frame.

The premolded and preassembled roof shape assembly part 1 is installed, and the outside perimeter of the roof is capped with the Z-shaped member part 19.

The exterior wall assembly part 3 containing insulated walls with or without windows, doors, or other openings is installed. Said exterior wall assembly part 3 has a Z frame part 9. At the top of the Z frame part 9 of the exterior wall assembly part 3 is welded part 10 as a continuous stop piece. For masonry exteriors, insert and weld part 20 to the bottom shelf of the Z frame part 9 of the exterior wall assembly part 3.

Between the intersecting parts of the floor and roof levels and the structural space frame, connecting piece 18 is inserted and secured by welding, bolting, or both depending upon the degree of permanency as to whether the completed house, apartment, or building is to be permanent, semipermanent, or demountable. At the exterior wall at the first floor deck the connecting piece part 18 is set in a vertical position to tie together the upper part of the base pedestal part 15 with the Z frame part 11 of the first floor deck assembly part 2, and the Z frame part 9 of the exterior wall assembly part 3, with or without the masonry ledge part 20.

At the exterior wall of a multistory construction at a typical floor deck, the connecting piece part 18 is set in a vertical position to tie together the upper part of one stanchion part 8 with the Z frame part 11 of the typical floor deck assembly part 2, the upper part of the Z frame part 9 of the exterior wall assembly part 3, and the lower part of the Z frame part 9 of the exterior wall assembly part 3. At the interior butting of the stanchions part 8, the connecting piece part 18 is secured to the Z frame part 11 of the fioor deck assembly part 2 within the thickness of the floor deck, and is secured to the Z frame part 11 of the roof base assembly part 2 within the thickness of the roof base.

The following additional work may also be done:

Fire retard the metals and also protect them from damage by the weather with paint or other coatings and applications. Install roof coverings, gutters, downspouts, and Weatherproof. Insert inetrior partitions, moldings, trim, miscellaneous components, equipments, cabinets, appliances, room surfaces, finishes, plumbing, and lighting fixtures, and all other exterior and interior parts and appointments. The work mentioned in this paragraph can be applied in the assembly plant or at the site, or be a combination of both. The hookup of all utilities, field preparation, and landscaping is performed at the site by others.

In the modular room plans, the component parts such as doors and windows, cabinets, appliances, and equipments items are not specifically designated, but the basic room combinations as a whole module or part of a module are noted by part numbers with a description of their function as follows:

Bedroom part 21, closets or alcoves part 22, passage or alcoves part 23, bathroom part 24, foyer or passage part 25, kitchen-laundry or utility part 26, dining room part 27, living room part 28, large bathroom or elevator part 29, office, spare room, utility room, classroom, screened or enclosed patio, garage or carport, miscellaneus part 30, stairway part 31, and spare room part 32. It is noted that areas can be larger; part 21 can be joined with part 28 to form a large living room.

It is understood that various changes in the shape, size, materials, arrangement of parts and modules of this invention may be resorted to.

What is new and therefore desired to be protected by Letters Patent of the United States is:

1. A housing structure comprising a space frame made up from a plurality of modular segments having nonbearing walls, each of said segments comprising:

independent stanchions vertically disposed at each corner of said segments to provide the entire load bearing support for the structure;

horizontal brace means between the ends of each of the adjacent of said stanchions to fix the relationship thereof to one another, said brace means having in cross section at least a web with webs transverse thereto extending from each side thereof;

a deck interfitting and supported by said brace means;

and

a pedestal assembly including adjustable levelling means disposed to support each of the stanchions of the lowermost of said segments.

2. A housing structure as defined in claim 1 wherein the horizontally adjacent of said segments are disposed with the floor decks thereof in coplanar relationship, said structure further comprising connecting means connecting adjacent stanchions at the top and bottom thereof.

3. A housing structure as defined in claim 2 wherein the stanchions of the vertically adjacent segments are disposed in aligned relationship, said structure further comprising connecting means connecting the adjacent ends of said stanchions.

4. A housing structure as defined in claim 3 wherein vertically adjacent modular segments have a floor deck serving also as a ceiling for the lower segment, the stanchions supporting the ceiling of the upper segment being fixed in upward extension from the corresponding stanchions of the lower segment.

5. A housing structure as defined in claim 4 further comprising a floor deck assembly, said assembly comprising framing members formed crosswise to distribute the load of the floor to the perimeter of the floor deck.

6. A housing structure as defined in claim 3 wherein said connecting means comprise an interlock having support means extending therefrom for supporting said floor decks.

7. A housing structure as defined in claim 6 further comprising Z-shaped structural sections extending between at least the tops of adjacent ones of said stanchions in each of said segments, the top leg of said structural sections being disposed on said stanchions and the bottom leg thereof extending inwardly into said segment to support the floor deck thereof.

8. A housing structure as defined in claim 6 wherein said connecting means comprise a bearing plate, prongs extending from each surface of said plate, and recesses in the ends of said stanchions to receive said prongs whereby horizontally and vertically adjacent ones of said stanchions are interconnected by inserting a corresponding prong of one of said bearing plates in the recesses thereof.

9. A housing structure as defined in claim 1 further comprising a preformed modular roof unit disposed on each of the topmost of said modular segments, said unit being formed so that when said modular segments are joined together the units combine to reflect the style and function of the structure.

10. A housing structure as defined in claim 1 further comprising a rigid frame for holding nonbearing Walls, said frame comprising a rectangle formed of Z-shaped structural sections the upper legs thereof facing inwardly to engage the periphery of an exterior side of said space frame for stiffening thereof.

References Cited UNITED STATES PATENTS 2,115,824 5/1938 McRorey 52126X 3,146,497 9/ 1964 Short et al. 52234 3,152,366 1'0/1964 McCrory et al. 5279 3,229,431 1/1966 Paul 5279X 3,292,327 12/1966 Van Der Lely 52236 3,378,971 4/1968 Singer et al. 52236X 3,421,271 1/ 1969 Whitfield 52126 3,430,398 3/1969 Green 5279 FOREIGN PATENTS 1,520,408 3/ 1969 France 52----79 757,683 9/1956 Great Britain 5279 572,894 2/1958 Italy 5279 PRICE C. FAW, IR., Primary Examiner US. Cl. X.R. 

